Container with insert having a fully or partially encapsulating seal with a frangible web formed against said insert

ABSTRACT

A blow-molded container is provided with an insert occluding its top opening. A closure structure at least partially encapsulates the insert article and includes a frangible web formed against the insert article. The container can be blow-molded in main mold halves and the closure structure, including the frangible web, can be formed by additional mold halves while the insert article is held in the container opening by an arm that is subsequently retracted or while the insert article is supported on a parison portion that defines the container body. In the latter instance a complete overcap for the insert article can be provided.

CROSS-REFERENCE TO RELATED APPLICATION

This is a division of application Ser. No. 402,982, filed Aug. 3, 1982,and now U.S. Pat. No. 4,596,110 which is a continuation-in-part ofapplication Ser. No. 296,368, filed Aug. 26, 1981.

TECHNICAL FIELD

This invention relates, in general, to molded containers with unitaryclosure seals and to methods and apparatus for producing suchcontainers.

BACKGROUND OF THE INVENTION

The above-identified U.S. patent application Ser. No. 296,368 discussesvarious patents disclosing methods and apparatus for forming, molding,filling and sealing a container. Further, that U.S. patent applicationdiscloses a container, as well as apparatus and methods for forming thecontainer, wherein a stopper or other insert is sealed in the top of thecontainer.

Specifically, a length of hollow tube parison is first extruded betweenthe main mold halves of a mold assembly. Then, while positioned betweenthe main mold halves, a parison portion is cut from the extruder and themold halves are moved to a station for blowing, molding and filling acontainer. Here the cut length of parison is positioned below a blowingand filling nozzle where the parison is molded into a container and thenfilled.

The stopper is initially carried by an insertion apparatus that has aninsertion member in the form of a cylindrical arm. When the blowing andfilling nozzle has been completely removed from the top opening of thefilled container, the insertion member that is carrying the stopper ismoved to position the insertion member and stopper over the container.The insertion member is then moved downwardly to deposit the stopperwithin the opening of the upwardly extending portion of the parisontube.

Then, sealing molds are closed to form the upper portion of the parisonaround the stopper to partially encapsulate the stopper. In one form ofthe disclosed method, a frangible web is formed by the sealing molds ina circumferential portion of the parison around and above the stopperwhile using the insertion member as an anvil.

A break-off tab or overcap may be subsequently formed above the stopperand frangible web, after the insertion member has been removed from theparison tube, by an additional set of upper sealing molds after theinsertion member is retracted. When the container contents are to bedispensed, the tab or overcap may be broken away at the frangible web toexpose an upper surface of the stopper and to permit the stopper to beremoved.

Although the above-discussed container and insert structure, as well asthe method and apparatus for fabricating such a structure, aresatisfactory in many applications, the inventor of the present inventionhas found that it would be desirable to provide a container with astopper or other insert at the top of the container wherein thefrangible web is located around the insert instead of above it.

Further, it would be desirable in some applications to provide such acontainer and insert structure without the container material extendingabove the insert. This would permit the container and insert structureto be fabricated with less material.

Additionally, it would be advantageous to provide in some applications amethod and apparatus for sealing a container with a multi-piece insertwherein the top of the container is hermetically sealed to each piece ofthe multi-piece insert and wherein a portion of at least one of theinsert pieces projects beyond the container and is exposed so that itmay be manipulated to open the container. With such a container andmulti-piece insert structure, it would be desirable to provide afrangible web in the container material around at least one of theinsert pieces to facilitate opening or fracture of the seal whendesired.

SUMMARY OF THE INVENTION

A container is formed from thermoplastic material and comprises a bodydefining an opening at one end, an insert article positioned at the bodyopening, and a closure structure unitary with the body portion. Theclosure structure encapsulates at least a portion of the insert articleto seal closed the container. The closure structure includes a wallmember unitary with the container and having first and second portionsjoined together with a frangible web that is formed by compression ofthe wall member, while in a plastic state, against the insert article toform a reduced thickness region defining the frangible web.

A novel method may be used for forming the container with the closurestructure encapsulating at least a portion of the insert article. Anextruded length of parison in the form of a vertically oriented,elongated, hollow tube is positioned in a closed main mold whilemaintaining an opening at the top of the remaining length of parisonabove the closed main mold as the container is formed from the parisonin the main mold.

An insert article is positioned within the hollow tube of parison at thetop of the molded container. Finally, at least some of the remaininglength of parison around at least a portion of the insert article iscompressed to seal the container to the insert article. The compressingstep includes urging the parison against the insert article to form areduced thickness region defining in a produced wall member a peripheralfrangible web joining first and second portions of the remaining parisonlength. When a container formed in the foregoing manner is to be used, asevering force, e.g., torque, may be applied to one of the first andsecond portions of the produced wall member to sever the frangible weband open an access to the container contents.

Apparatus for effecting the above-described method for forming the novelcontainer and insert structure includes means for initially forming thecontainer body with an open top, gripping means for maintaining anopening at the top of the length of parison above the container body,and sealing mold means for sealing the top of the formed container. Thisapparatus is further characterized in that a positioning means isprovided for positioning the insert article at the container top openingand that the sealing mold means has a unique configuration.

Specifically, the sealing mold means includes molding means closableabout the insert article and the surrounding parison for controllablycompressing the parison between the insert article and the molding meansto thereby seal the formed container against at least a portion of theinsert article. The sealing mold means also includes a frangible webforming means associated with the molding means for further molding aportion of the compressed parison to form a reduced thickness regiondefining the frangible web.

Numerous other features of novel containers, methods for fabricating thecontainers, and an apparatus for fabricating the containers will beapparent from the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings forming part of the specification, and inwhich like numerals are employed to designate like parts throughout thesame,

FIG. 1 is a side view of a first embodiment of a container of thepresent invention with a partially encapsulated composite insertarticle, specifically a threaded closure;

FIG. 2 is an enlarged, fragmentary, partial cross-sectional view takenalong the plane 2--2 in FIG. 1;

FIGS. 3-5 are schematic diagrams, partly in section, generallyillustrating the manner in which the container of FIGS. 1 and 2 isfabricated;

FIG. 6 is a fragmentary, side view of a modified form or secondembodiment of a container with a fully encapsulated composite insertarticle;

FIG. 7 is a schematic diagram, partly in section with the container ofFIG. 6 rotated 90°, generally illustrating the manner in which thecontainer of FIG. 6 is fabricated;

FIG. 8 is a top plan view of a third embodiment of a container of thepresent invention with a fully encapsulated composite insert article;

FIG. 9 is a greatly enlarged, fragmentary, partial, cross-sectional viewtaken along the plane 9--9 in FIG. 8;

FIG. 10 is a fragmentary, front view of a fourth embodiment of acontainer of the present invention having an insert article sealedwithin a frangible encapsulating wall and having an external threadedcap;

FIG. 11, on the sheet of drawings with FIGS. 13 and 14, is a greatlyenlarged, fragmentary, cross-sectional view taken along the plane 11--11in FIG. 10;

FIG. 12, on the sheet of drawings with FIGS. 8, 9, and 12, is a viewsimilar to FIG. 10 but showing the threaded cap removed and theencapsulating wall severed from around a portion of the insert article;

FIG. 13 is a top plan view of a fifth embodiment of a container of thepresent invention having (1) an insert article with a first threaded capthat are together sealed within a frangible encapsulating wall and (2) asecond, external threaded cap; and

FIG. 14 is a greatly enlarged, fragmentary, partial cross-sectional viewtaken along the plane 14--14 in FIG. 13.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention may be used in many different forms. The specificationand the accompanying drawings disclose only a few specific forms as anexample of the use of the invention. The invention is not intended to belimited to the embodiments illustrated, and the scope of the inventionwill be pointed out in the appended claims.

The precise shapes and sizes of the components herein described are notessential to the invention unless otherwise indicated.

For ease of description, the apparatus of this invention will bedescribed in the normal (upright) operating position. Terms such asupper, lower, horizontal, etc., will be used reference to this position.It will be understood, however, that the apparatus of this invention maybe manufactured, stored, transported, used, and sold in an orientationother than the position described.

The apparatus of this invention has certain conventional drivemechanisms and control mechanisms the details of which, although notfully illustrated or described, will be apparent to those having skillin the art and an understanding of the necessary functions of suchmechanisms.

The present invention incorporates many of the method steps and much ofthe apparatus disclosed in the copending U.S. patent application Ser.No. 296,368 discussed above under the section entitled "Cross-Referenceto Related Application." The disclosures of that application areincorporated herein by reference thereto to the extent that suchdisclosures are pertinent and not inconsistent with the presentspecification.

For ease of understanding the present invention, a thermoplasticcontainer will first be described. This will be followed by adescription of the method for molding the container, filling thecontainer from the top, positioning an insert article at the top of thecontainer, and then sealing the top of the container against the insertarticle to form a frangible web within a container closure structure.

Next, second through fifth embodiments of a thermoplastic container willbe described along with the methods for fabricating such containers.

THE CONTAINER: FIRST EMBODIMENT

A first embodiment of a formed, filled, and sealed container 50A isillustrated in FIGS. 1 and 2. The container 50A is preferably fabricatedfrom conventional thermoplastic molding materials such as polyethylene(low or high density), polypropylene, and the like materials compatiblewith the container content.

The teachings of the present invention find application in theproduction of filled and unfilled containers having a wide variety ofshapes and sizes. Typically, such containers have a volume ranging frombetween about 5 milliliters to between about 1 or 2 liters.

The container 50A is an example of one such container and includes agenerally cylindrical, hollow body or body portion 52A having a bottom54A and a top or top portion 56A. The top 56A of the container bodyportion 52A terminates in a closure structure 58A.

The container closure structure 58A may be one of a variety of designs.For example, the closure structure 58A may be designed to hold or retaina stopper or may include a pierceable membrane. The stopper or themembrane may be pierced with a cannula, spike, hypodermic syringe, orthe like, by which the container contents 51A may be withdrawn.Alternatively, the closure structure 58A may permit complete removal ofan encapsulated stopper. In another embodiment, the closure structure58A may hold or retain a dispensing nozzle instead of a stopper per se.

In the first embodiment of the container 50A illustrated in FIGS. 1 and2, the top closure structure 58A holds or retains a composite insertarticle or auxillary component comprising a nozzle assembly thatincludes (1) a dispensing tip or nozzle 72A, (2) a connected base 73A,and a cap 75A.

The nozzle base 73A comprises (1) an upper cylindrical portion 76A, (2)a lower, reduced diameter cylindrical portion 78A, and (3) afrustoconical portion 80A joining the upper portion 76A to the lowerportion 78A.

The upper portion 76A of the base 73A has a beveled edge 83A joining anupwardly facing annular flat surface (not visible in FIGS. 1 and 2)which surrounds and merges with the nozzle 72A. The base lower portion78A also includes a beveled edge or bearing surface 82A.

The nozzle 72A includes the usual dispensing bore or aperture 74Aextending from the upper distal end of the nozzle, through the nozzle,and to the bottom of the nozzle base 73A. The nozzle 72A also includes aconventional exterior thread 86A onto which the cap 75A may be screwed.To this end, the cap 75A includes a suitable mating internal threadstructure 87A.

As best illustrated in FIG. 2, the thermoplastic material of the closurestructure 58A forms an upstanding wall member that surrounds the nozzleassembly base 73A and extends upwardly to partially encapsulate thelower portion of the cap 75A. In particular, the closure structure 58Asealingly encapsulates the nozzle base 73A and is sealingly engaged witha portion of the lower beveled edge bearing surface 82A, thefrustoconical portion 80A, the upper cylindrical portion 76A, the upperbeveled edge 83A, and the enlarged cylindrical lower portion of the cap75A.

The term "closure structure", as used in the specification and in theclaims, refers to the thermoplastic material (such as 58A in FIG. 2)that extends upwardly of the container body top portion (such as topportion 56A in FIG. 2) and that is sealingly engaged with the insertarticle (such as the base 73A of the nozzle 72A and the cap 75A in FIG.2). In the first embodiment illustrated in FIGS. 1 and 2, this closurestructure 58A is thus seen to be unitary with both the container bodyportion 52A and the container top portion 56A. The closure structure 58Aencapsulates at least a portion of the composite insert article to sealclosed the container and, as described hereinafter for some alternateembodiments, the closure structure 58A may completely encapsulate thecomposite insert article.

The closure structure 58A can be more specifically defined as includinga peripheral wall having a first or lower portion 59A and a second orupper portion 61A which are joined together with a frangible web orreduced thickness region 94A of the molded thermoplastic material. Thefrangible web 94A is formed, as will be explained in detail hereinafter,by compression of the closure structure thermoplastic material whileplastic against the composite insert article (the exterior surface ofthe cap 75A) to form an annular notch or reduced thickness regiondefining the frangible web 94A between the first wall portion 59A andthe second wall portion 61A. Frangible web 94A abuts the insert article,in particular, the side wall of cap 75A.

When it is desired to gain access to the contents 51A of the container50A, force may be applied to the wall portions 59A and 61A to sever thefrangible web 94A. This can be effected, for example, by peeling orpulling away from the cap 75A the upper or second wall portion 61A ofthe closure structure 58A so that wall portion 61A is torn or severedfrom the remainder of the structure along the frangible web 94A.Alternatively, unscrewing the cap 75A from the nozzle 72A will cause theupper or second wall portion 61A of the closure structure 58A to besevered from the remainder of the closure structure 58A at the frangibleweb 94A. Removal of the cap 75A completely from the nozzle 72A thuspermits the contents 51A of the container 50A to be dispensed throughthe nozzle 72A.

METHOD AND APPARATUS FOR MAKING THE FIRST EMBODIMENT OF THE CONTAINER

The preferred method for forming the first embodiment of the container50A illustrated in FIGS. 1 and 2 will next be described with referenceto FIGS. 3-5. These figures progressively illustrate the sequence of thesteps of the method.

The novel method steps of the present invention may be effected toposition an insert article at the top opening of the container and toform a closure structure unitary with the container for encapsulating atleast a portion of the insert article. Typically, the body of thecontainer is initially formed by conventional methods and/or by themethod fully described in the above-identified U.S. patent applicationSer. No. 296,368.

U.S. patent application Ser. No. 296,368 describes in detail a methodfor blow molding a container from thermoplastic material as illustratedin FIGS. 3-5 of that patent application and reference is directedthereto. Basically, a length of parison 200 is extruded from aconventional extruder head in the form of a vertically oriented,elongated, hollow tube of a semi-molten thermoplastic material, i.e., ina plastic state. Before, during or after the parison 200 is extruded tothe desired length, a mold assembly is positioned in spaced relationshipfrom and around the parison 200.

Next, with the upper end of the parison 200 prevented from collapsing bythe holding jaws 312 and 314A, the parison 200 is severed, above theholding jaws 312A and 314A and below the extruder head (not illustrated)in a conventional manner, i.e., by means of a moving cutter, such as ahot wire, a blade, or the like (not illustrated). The mold assemblyitself is designated generally by reference numeral 300. The moldassembly includes a lower, first, or main mold comprising mold half 302and mold half 304. The assembly also includes a pair of two coactingsecond or upper sealing mold halves 308A and 310A as well as thepreviously mentioned pair of two vacuum operable holding jaws 312A and314A.

The first or main mold halves 302 and 304 cooperate when moved togetherto define a first cavity for the container 50A. The inside surfaces ofthe mold halves 302 and 304 serve to mold the thermoplastic material todefine the sidewall of the container body portion 52A, the containerbottom (not visible in FIG. 3), the container top 56A, and a lowerportion of the container closure structure 58A (not yet fully formed inFIG. 3 but illustrated as fully formed in FIGS. 1 and 2).

In FIG. 3 the first or main mold halves 302 and 304 are shown in aclosed position around the container 50A. The mold halves 302 and 304have been moved to the closed position from an open position in whichthey were spaced apart by a distance sufficient to permit the parison200 to hang between them. The main mold halves 302 and 304 are movedtogether to the closed position by suitable means, such as a fluidcylinder actuator or actuators (not illustrated).

The second or upper sealing mold halves 308A and 310A are preferablypositioned in sliding engagement with the tops of the first or main moldhalves 302 and 304, respectively. The second or upper sealing moldhalves 308A and 310A are preferably directly carried by the first ormain mold halves 302 and 304, respectively, and are thus movable withthe main mold halves 302 and 304 between (1) the main mold open positionillustrated in FIG. 5 and (2) the main mold closed position illustratedin FIG. 3.

The upper sealing mold halves 308A and 310A are also capable of movementrelative to the main mold halves 302 and 304. Specifically, when themain mold halves 302 and 304 are in the main mold closed positionillustrated in FIG. 3, the second or upper sealing mold halves 308A and310A can be moved by suitable conventional actuators (not illustrated)to a sealing position (FIG. 4) to form the container closure structure58A (FIGS. 1 and 2) as will be described in detail hereinafter.

The vacuum operable holding jaws or parison grippers 312A and 314A areadapted to be moved between an extended gripping position and aretracted position. Means for effecting such movement may be providedseparately of the means for moving the first and second main mold halves302 and 304. However, jaws 312A and 314A are preferably mounted formovement with the first mold halves 302 and 304. Thus, when the firstmain mold halves 302 and 304 are in the open position (FIG. 5), theholding jaws 312A and 314A are spaced from the parison 200. When thefirst mold halves 302 and 304 are in the closed position illustrated inFIG. 3, the holding jaws 312A and 314A, having moved with the first ormain mold halves 302 and 304, are adapted to engage a portion of theparison 200 extending upwardly above the closed first mold halves 302and 304. The jaws 312A and 314A grip the parison 200 by means of areduced pressure or vacuum (as effected by suitable conventional meansnot illustrated) between the surface of the 200 parison and the grippingsurfaces of the holding jaws 312A and 314A.

When the first or main mold halves 302 and 304 are in the closedposition illustrated in FIG. 3, the holding jaws 312A and 314A are inthe extended gripping position and ready to engage the upper end of theparison 200 that extends above the first and second pairs of moldhalves. At this point in the process, pressurized air is discharged fromthe extruder head (not illustrated) through a suitable conventional tube(not illustrated) to expand the parison 200 slightly so that it comesinto contact with the parison grippers or holding jaws 312A and 314A asillustrated in FIG. 3. This parison expansion process is conventionaland well known to those skilled in the art. The holding grippers 312Aand 314A, through the vacuum or reduced pressure effected between theparison 200 and the inner surfaces of the jaws 312A and 314A, maintainan opening in the upper end of the parison.

Typically, a number of containers 50A are fabricated at one time in amulti-cavity mold assembly. For ease of description, only one moldcavity is illustrated. It is to be realized, however, that the moldassembly 300 may include a plurality of cavities aligned in a row andthat a plurality of extruder heads may be provided in a row forextruding a length of parison into each cavity.

The mold assembly 300 is typically mounted on a hydraulically-actuatedmold carriage (not illustrated in the simplified schematic diagrams ofFIGS. 3-5) which moves the mold assembly, including the holding jaws312A and 314A, into the proper parison receiving position below theextruder head (not illustrated). The carriage also functions tosubsequently carry the mold assembly 300, with holding jaws 312A and314A, from the parison receiving position beneath the extruder head to aposition displaced from the extruder head where the severed lengthparison 200 is molded i.e. (blown or vacuum-formed) into a containershape, then filled, and finally sealed. One such carriage, integral witha complete molding apparatus, is described in detail with reference tothe above-identified U.S. patent application Ser. No. 296,368 andreference is directed thereto.

After the parison 200 has been severed from the extruder, the moldassembly 300 is moved by the mold assembly carriage (not illustrated)along with holding jaws 312A and 314A away from the extruder head (notillustrated) in a direction normal to the plane of FIG. 3. The moldcarriage typically moves the mold assembly 300 with holding jaws 312Aand 314A a distance of about 30 centimeters to the molding, filling,inserting and sealing station wherein the severed length of parison ismolded, filled, provided with an insert and sealed as will next beexplained.

The molding, filling, inserting and sealing station is illustrated inFIG. 3 where the container 50A is shown as having been molded and filledwith liquid contents 51A. Molding can be effected by blow forming,vacuum forming, or a combination of both of the foregoing expedientsdepending on container size. At this station, a vertically reciprocablecomposite blowing and filling mandrel (not illustrated) is providedalong with a vertically reciprocable insert article pick up andplacement arm 600A (FIG. 3).

The blowing and filling mandrel is described in detail with reference tothe above-identified U.S. patent application Ser. No. 296,368 andreference is directed thereto wherein a composite blowing and fillingmandrel 500 is described with reference to FIGS. 5 and 15-19 of thatpatent application.

In addition to being vertically reciprocable, both the composite blowingand filling mandrel and the arm 600A are laterally reciprocable.Preferably, in the preferred embodiment, the composite blowing andfilling mandrel and the arm 600A are carried on a suitable commonstructure or carriage (not illustrated) for effecting a common lateralreciprocation of the composite mandrel and arm 600A. Such a carriage foreffecting common lateral reciprocation of a composite mandrel and aninsert article pick up and placement arm is described in theabove-identified U.S. patent application Ser. No. 296,368. Reference isdirected thereto for the description of such a carriage for a compositemandrel 500 and for an arm 600 (which is functionally analogous to thearm 600A described and illustrated herein).

In any case, with the severed parison 200 properly positioned at themolding, filling, inserting and sealing station, the composite blowingand filling mandrel is in registry (or is moved into registry) with theopening at the upper end of the severed length of the parison. Then thecomposite mandrel is extended downwardly into the opening of the upperend of the severed length of the parison to seal the parison openingwith the mandrel and to press the parison against the first or main moldhalves 302 and 304.

The composite mandrel preferably includes a conventional blowing tubeand a conventional filling tube. The composite mandrel may be of asuitable conventional design such as the mandrels disclosed in theabove-discussed U.S. patent application Ser. No. 296,368 or U.S. Pat.No. 3,919,374 and/or found in commercial machines that incorporate asingle mandrel for molding and filling the container.

In operation, compressed gas, such as air or the like, is dischargedthrough the mandrel blowing tube into the interior of the hollow parisonto inflate the parison outwardly against the walls of the cavity definedby the first or main mold halves 302 and 304 with or without vacuumassist through small passageways in the molds. The compressed gas istypically discharged for about one second. Next, the filling tube insidethe composite mandrel is reciprocated downwardly to open a vent passagein the mandrel to permit venting of the compressed gas out of the moldedcontainer. Subsequently, the blowing tube is moved downwardly a smallamount within the mandrel to open the product dispensing valve andpermit the product to be injected under pressure from the filling tubeinto the formed container.

The product, typically a liquid (indicated by reference numeral 51A andalready filling the container 50A in FIG. 3), is usually at a relativelylower temperature than the parison and assists in solidifying the wallsof the formed container. After the formed container 50A has been filledwith the desired amount of product 51A, the composite mandrel iswithdrawn from the open end of the parison. If it is desired to form anunfilled container, the filling procedure, of course, is omitted fromthe manufacturing process.

When the composite blowing and filling mandrel has been elevated to aposition above the holding jaws 312A and 314A, the composite mandrel ismoved away from the parison open end while the pick up and placement arm600A is moved into alignment or registry with the opening at the upperend of the parison. The arm 600A then is extended downwardly into theparison as illustrated in FIG. 3.

The pick up and placement arm 600A functions to perform a secondaryoperation through the parison top opening on the remaining length ofparison 200 above the closed main mold halves 302 and 304. Specifically,the arm 600A functions to position an insert article or auxiliarycomponent within the remaining length of parison 200 above the closedmain mold halves, which auxiliary component is ultimately fully orpartially encapsulated in the container top closure structure.

In the method illustrated in FIGS. 3-5, the arm 600A is shown aspositioning the composite insert article (comprising the assembly of thenozzle 72A and cap 75A) in the parison opening for subsequent partialencapsulation by the parison 200.

The particular configuration illustrated for the composite insertarticle (nozzle 72A and cap 75A) is not essential to the novel methodtaught herein. The method may be used with single or multi-piecearticles having various shapes.

The insert article (such as nozzle 72A and cap 75A) is held in asuitable manner by the arm 600A. One such suitable manner includes theuse of vacuum drawn in a cylindrical holding or receiving cavity 602A atthe bottom end of the arm 600A against which is positioned the insertarticle. The insert article can also be held by arm 600A using amechanical retention means such as friction, a snap-fit releasableinterlock, or other means.

When using a vacuum-assisted pick up action, the distal end of the pickup arm 600A defines a generally downwardly facing annular sealingsurface 604A which contacts an upper surface of the insert article (suchas the top of the base portion of the cap 75A as illustrated). The arm600A defines a suitable bore 606A which communicates with the receivingcavity 602A. The bore 606A is connected to a suitable source of vacuum(not illustrated). A reduction in pressure is effected through the bore606A and the insert article (such as nozzle 72A and cap 75A) is thusmaintained in the bottom of the pick up arm 600A by means of thepressure differential between the reduced pressure in the receivingcavity 602A and ambient atmospheric pressure.

The structure of the pick up arm 600A need not be limited to thatdescribed above with reference to FIG. 3. Depending upon the shape ofthe insert article, other structures may be used. An example of anotherform of a pick up arm is described in the above-identified U.S. patentapplication Ser. No. 296,368 with reference to arm 600 illustrated inthe various figures of that patent application.

The insert article may be automatically positioned on the end of thepick up arm 600A by suitable apparatus. Although such suitable articleplacement apparatus is not described or illustrated herein, one designfor a stopper insert article is described in the above-identified U.S.patent application Ser. No. 296,368 with reference to feeder apparatus700 and transfer apparatus 720 illustrated in the various figures ofthat patent application.

In any case, the insert article pick up arm 600A, with the insertarticle placed thereon, is extended downwardly and aligned verticallywithin the upper opening of the parison 200 adjacent the second or uppersealing mold halves 308A and 310A.

Preferably, the pick up arm is extended downwardly a sufficient amountto force the bottom of the insert article (e.g., the bottom lowerbeveled edge or bearing surface 82A of the nozzle base) against ashoulder portion 49 of the parison defining a part of the top opening ofthe container 50A. This shoulder portion 49 of the parison may besomewhat reduced in thickness compared to the other wall portions of thecontainer 50A owing to a slight compression of the shoulder portion 49by the composite blowing and filling mandrel during the prior step ofblow molding and filling the container.

As can be seen with reference to FIG. 3, the sealing mold halves 308Aand 310A have interior surfaces 320A that define a central cavityportion conforming to the exterior shape of the nozzle and cap insertarticle. When the sealing mold halves 308A and 310A are ultimatelyclosed, the diameter of the sealing mold cavity, taken at any verticalposition along the longitudinal vertical axis of the mold, is slightlylarger than the corresponding exterior diameter of the insert article soas to accommodate the desired thickness of parison during the sealingstep.

To effect the sealing step, the second or upper sealing mold halves 308Aand 310A are moved from their open position (FIG. 3) to their closed orsealing position (FIG. 4) to compress at least some of the parisonagainst at least a portion of the insert article to hermetically sealthe top of the container 50A to the insert article. The pick up arm 600Acan then be retracted upwardly to a position above the parison tube andabove the gripper holding jaws 312A and 314A. If desired, the vacuumeffected at the bottom of the pick up arm 600A can be terminated justbefore the arm 600A is raised. However, since the insert article istightly engaged by the parison between the closed upper sealing moldhalves 308A and 310A, continuous maintenance of the vacuum throughoutthe operation, including during and after retraction of the pick up arm600A, will not prevent proper release of the insert article from thepick up arm 600A.

In accordance with the teachings of the present invention, the uppersealing mold halves 308A and 310A can be regarded generally as sealingmold means for sealing closed the container 50A. However, it is theinterior molding surfaces 320A of the second or upper sealing moldhalves 308A and 310A that can be said to function specifically as themolding means closable about the insert article and the surroundingparison 200 for compressing the parison between the insert article andthe molding surfaces 320A to thereby seal the formed container 50Aagainst at least a portion of the insert article.

The second or upper sealing mold means or mold halves 308A and 310A alsoinclude a forming means 350A for forming the frangible web 94A. The webforming means 350A preferably includes an inwardly projecting annularmember or protrusion. The inwardly directed protrusion 350A functions asa frangible web forming means associated with the molding surfaces 320Afor compressing further a portion of the parison against the exteriorsurface of the insert article to form a reduced thickness regiondefining the frangible web 94A. As described above in detail withreference to FIGS. 1 and 2, the frangible web 94A facilitates thedestruction of at least a portion of the seal at the insert article sothat access may be had to the insert article and so that the containercontents 51 may be dispensed from the container 50A.

If desired, a knife edge 370A can be provided on the second or uppersealing mold halves 308A and 310A as best illustrated in FIGS. 3 and 4.When the sealing mold halves 308A and 310A are closed against the insertarticle, the knife edge 370A becomes positioned relatively close to thecylindrical exterior surface of the pick up arm 600A. This causes theknife edge 370A to penetrate through a substantial portion of theparison above the second or upper wall portion 61A (FIG. 4) of theclosure structure 58A. As a result, the segment of the parison 200extending upwardly above the upper wall portion 61A is almost, but notquite, severed from the top of the container 50A. Ultimately, thispartially severed segment of the parison 200 is completely removed fromthe container 50A, as by breaking the segment off of the container byhand or with a suitable conventional automatic deflashing apparatus (notillustrated) known in the art.

After the pick up arm 600A has been raised to an elevated position abovethe holding jaws 312A and 314A, the molds are opened as best illustratedin FIG. 5. Specifically, the first or lower (main) mold halves 302 and304 are opened. The second or upper sealing mold halves 308A and 310A,being carried on the main mold halves, necessarily also move away fromthe container 50A. In addition, the upper sealing mold halves 308A and310A are independently moved relative to the main mold halves 302 and304 to the extreme open position illustrated in FIG. 5.

In the preferred embodiment, the holding jaws 312A and 314A are movedtogether with, or mounted to, the first or main mold halves 302 and 304(with conventional mounting means not shown in the schematicrepresentation of FIGS. 3-5). Therefore, in this particular arrangementthe holding jaws 312A and 314A are moved to the retracted (open)position when the main mold halves 302 and 304 are moved to the openposition as illustrated in FIG. 5.

When the mold assembly 300 is fully open, the formed and filledcontainer 50A is thus free and clear of the mold assembly and may beremoved and deflashed by suitable conventional means. Typically, thecontainer 50A can be supported on a movable pin (not illustrated)encapsulated in the flash at the bottom of the container in a mannerwell known in the art. The container 50A could then be removed from themold area on the pin and transferred to a suitable conventionaldeflashing apparatus. During deflashing, the projecting flash (at thebottom of the container 50A, around the sides of the container, and theupwardly extending portion of the parison above the upper wall portion61A) are broken away to provide a deflashed container substantially asillustrated in FIGS. 1 and 2.

In preparation for the next molding cycle, the pick up arm 600A andcomposite blowing and filling mandrel (not illustrated) are returned totheir original positions wherein the mandrel is positioned over the moldassembly center line. In that position, the mandrel is ready to beginthe next forming and filling cycle after the mold assembly has beenmoved to the extruder to receive a new length of parison and thenreturned to the molding, filling, inserting and sealing station with theparison located below the mandrel.

THE CONTAINER: SECOND EMBODIMENT

A second embodiment of a container of the present invention isillustrated in FIGS. 6 and 7 wherein the container is designatedgenerally by reference numeral 50B. The container 50B has a generallycylindrical, hollow body portion 52B substantially similar to the body52A of the first embodiment of the container 50A illustrated in FIGS.1-2. Similarly, the second embodiment of the container 50B has a topclosure structure 58B in which is mounted, and which retains, anauxiliary component that is a nozzle assembly having a nozzle with abase 73B and a cap 75B. The nozzle assembly is identical to the nozzleassembly of the first embodiment of the container 50A described abovewith reference to FIGS. 1-5.

The container 50B is substantially identical to the container 50Aillustrated in FIGS. 1-2 except that the top of the closure structure58B is completely sealed over the insert article and has a means bywhich the sealed portion may be broken to permit access to the article.In particular, at the top of the closure structure 58B there is provideda hollow shell or overcap structure 92B that is joined to the lowerportion of the closure structure 58B by means of a frangible web orreduced thickness portion 94B of the molded thermoplastic material. Theweb 94B joins a lower or first wall portion 59B to an upper or secondwall portion 61B and the exterior surface of the frangible web 94B isseen to define an annular notch. Also, two flat tabs 96B are provided onthe sides of the overcap structure 92B.

When it is desired to gain access to the contents of the container 50B,force is applied to sever the frangible web 94B. For example, whileholding the container body 52B, the overcap 92B can be grasped, with thethumb and forefinger pushing on opposite sides on the tabs 96B, so as toapply a rotational force or torque to the wall portion below the web 94Band an opposite torque to the wall portion above the web 94B. This willbreak the frangible web 94B whereby the overcap 92B can be removed fromthe container 50B. Access is thus provided to the top of the insertarticle. If the insert article comprises the above-described nozzleassembly, then the nozzle cap 75B can be unscrewed to permit thecontainer contents 51B to be dispensed.

METHOD AND APPARATUS FOR MAKING THE SECOND EMBODIMENT OF THE CONTAINER

FIG. 7 schematically illustrates the manner in which the container 50Bof FIG. 12 may be fabricated. In particular, the container 50B isinitially formed and filled in the manner identical to that for formingand filling the first embodiment of the container 50A described abovewith reference to FIGS. 3-5. To this end, the lower or main mold halves302 and 304 are provided along with the gripper holding jaws 312B and314B. The main mold halves 302 and 304 are identical to the main moldhalves described above with reference to the method for forming thefirst embodiment of the container 50A. Similarly, except for anincreased elevation distance above the main mold halves 302 and 304,holding jaws 312B and 314B are identical to jaws 312A and 314A,respectively, described above with reference to the method for formingthe first embodiment of the container 50A.

Second or upper sealing mold halves 308B and 310B are provided above themain mold halves 302 and 304 and below the jaws 312B and 314B. The uppersealing mold halves 308B and 310B are generally similar to the sealingmold halves 308A and 310A described above with reference to FIGS. 3-5.However, the upper sealing mold halves 308B and 310B do not have theknife edge structure 370A that was provided in the upper sealing moldhalves 308A and 310A described above with reference to FIGS. 3-5.Rather, the upper portions of the sealing mold halves 308B and 310Bdefine a generally cylindrical cavity 372B to accommodate the parisonbetween the sealing mold halves (308B, 310B) and the exterior of theinsert article.

The sealing mold halves 308B and 310B do define an inwardly projectingannular member or forming means 350B for forming the frangible web 94Bin a manner analogous to the member 350A of the mold halves 308A and310A described above (with reference to FIGS. 3-5). Specifically, thefrangible web forming means 350B functions to compress further a portionof the parison against the exterior surface of the insert article toform a reduced thickness region defining the frangible web 94B. Theconfiguration of the frangible web forming means 350B on the uppersealing mold halves 308B and 310B is designed to provide, for a givenclosure structure diameter and wall thickness, the desired frangible webthickness so that the frangible web 94B, while maintaining the necessarystructural integrity during normal handling of the sealed container 50B,can be broken when sufficient force is applied to the formed overcap92B.

In addition to the modified upper sealing mold halves 308B and 310B, themold assembly for molding the modified container 50B includes a thirdmold means or pair of third mold halves 340B and 342B. The third moldhalves 340B and 342B are movable relative to the main mold halves 302and 304 and can be movable also with respect to the sealing mold halves308B and 310B, if desired. Specifically, the third mold halves 340B and342B are movable between the retracted position (not illustrated) andthe closed or sealing and overcap-forming position illustrated in FIG.7.

When the insert article is positioned between the sealing mold halves308B and 310B (as with the transfer arm 600A described above withreference to FIGS. 3-5), the sealing mold halves 308B and 310B areclosed to partially encapsulate the insert article. The third moldhalves 340B and 342B can remain open during this step in the process orthey can move together with mold halves 308B and 310B if the insertarticle positioning arm is retracted. The frangible web is formed by theforming means 350B of the sealing mold halves 308B and 310B coactingwith the cylindrical exterior surface of the base of nozzle cap 75B.

Next, the first or main mold halves 302 and 304 are returned to the openposition as well as the sealing mold halves 308B and 310B, the third orovercap-forming mold halves 340B and 342B, and the gripper jaws 312B and314B. The formed container 50B, clear of the mold assembly, can thus beremoved and moved to suitable apparatus for deflashing.

THE CONTAINER: THIRD EMBODIMENT

A third embodiment of the container of the present invention isillustrated in FIGS. 8 and 9 wherein the container is designatedgenerally by the reference numeral 50C. As best illustrated in FIG. 8,the container 50C has a body portion or body 52C that when viewed fromthe top, is somewhat square with slightly convex sides and curvedcorners. The body 52C is hollow and otherwise similar to the body 52A ofthe first embodiment of the container 50A illustrated in FIGS. 1-2.

The container 50C has a top closure structure 58C in which is mounted,and which retains, an auxliary component or insert article--in this casecomprising a nozzle assembly having a base 73C and a cap 75C. The nozzleassembly is identical to the nozzle assembly of the first embodiment ofthe container 50A described above with reference to FIGS. 1-5 and isalso identical to the nozzle assembly of the second embodiment of thecontainer 50B described above with reference to FIGS. 6 and 7.

The closure structure 58C that is completely sealed over the insertarticle nozzle assembly and has a means by which the sealed portion maybe broken to permit access to the nozzle assembly as is explained indetail below. The closure structure 58C is very similar to the closurestructure 58B of the second embodiment of the container 50B describedabove with reference to FIGS. 6 and 7. Consequently, the elements of thethird embodiment that are identical or functionally analogous to thoseof the second embodiment are designated by reference numerals identicalto those used in FIGS. 6 and 7 for the second embodiment with theexception that the third embodiment reference numerals are followed bythe capital letter C whereas the second embodiment reference numeralsare followed by the capital letter B.

The closure structure 58C is provided with a hollow shell or overcapstructure 92C that is joined to the lower portion of the closurestructure 58C by means of a frangible web or reduced thickness portion94C of the molded thermoplastic material. The frangible web 94C isformed between a wall first or lower portion 59C and a wall second orupper portion 61C. The web and wall portions are identical to thecorresponding elements of the second embodiment illustrated in FIGS. 6and 7. However, the overcap structure 92C is different.

Specifically, the overcap structure 92C includes a first, hollow,cylindrical portion 92C' and a second, hollow, cylindrical portion 92C"having a relatively smaller outside diameter. The overcap structure 92Cis further provided with outwardly extending and tapered flat tabs orwings 96C that are considerably larger than the tabs 96B of the secondembodiment illustrated in FIG. 6 and that extend substantially along theentire height of the overcap cylindrical portions 92' and 92C", and downto wall upper portion 61C. This particular tab or wing configuration iswell suited for use with relatively tough materials of construction suchas polypropylene.

The method used to gain access to the contents of the container 50C issubstantially identical to that employed to gain access to the contentsof the second embodiment container 50B discussed above.

METHOD AND APPARATUS FOR MAKING THE THIRD EMBODIMENT OF THE CONTAINER

The method and apparatus for making the third embodiment of thecontainer 50C are generally equivalent to the method and apparatus,respectively, for making the second embodiment of the container 50Bdiscussed above with reference to FIGS. 6 and 7.

THE CONTAINER: FOURTH EMBODIMENT

A fourth embodiment of a container of the present invention isillustrated in FIGS. 10-12 wherein the container is designated generallyby reference numeral 50D. The elements of the fourth embodiment that areidentical or functionally analogous to those of the second and thirdembodiments are designated by reference numerals identical to those usedfor the second and third embodiments with the exception that the fourthembodiment reference numerals are followed by the capital letter Dwhereas the second and third embodiment reference numerals are followedby the capital letters B and C, respectively.

The container 50D has a hollow body portion or body 52D substantiallysimilar to the body 52C of the third embodiment of the container 50Cillustrated in FIGS. 8 and 9.

Similarly, the fourth embodiment of the container 50D has a top closurestructure 58D in which is mounted, and which retains, an auxiliarycomponent that includes insert assembly 71D (FIG. 11).

Assembly 71D includes a base 73D seated on an annular shoulder 57D ofthe top portion 56D of the container body 52D and includes a dischargeconduit 72D defining the usual dispensing bore or aperture 74D extendingfrom the upper distal end or nozzle of the conduit 72D, down through theconduit 72D, and to the bottom of the nozzle base 73D. The conduit 72Dalso includes an exterior annular flange or ridge 86D against which theparison is ultimately formed as will be described in more detailhereinafter.

The insert assembly base 73D includes a first frustoconical wall 73D'extending downwardly from the discharge conduit 72D, a secondfrustoconical wall 73D" extending downwardly from the firstfrustoconical wall 73D', and a seating shoulder 73D'" defined at thejunction of the first and second frustoconical walls for seating theinsert assembly 71D on the top portion 56D of the body 52D at the bodyopening. The insert assembly 71D also preferably includes a pierceablemembrane 72D' extending across the bore 74D to occlude flow from theinsert assembly 71D.

As best illustrated in FIGS. 10 and 11, the container 50D has a closurestructure 58D that is completely sealed over the nozzle assembly 71D andincludes means by which the sealed portion of the closure structure maybe broken to permit access to the nozzle assembly 71D. In particular,the closure structure 58D can be more specifically defined as includinga peripheral wall having a first or lower portion 59D and a second orupper portion 61D which are joined together with a frangible web orreduced thickness region 94D between the wall first portion 59D and thewall second portion 61D.

The frangible web 94D abuts the insert article, in particular, thesidewall of the nozzle assembly discharge conduit 72D. The wall secondportion 61D extends outwardly from the discharge conduit 72D and definesan exterior thread 100D. The wall second portion 61D also merges with ahollow shell or overcap structure 92D which is spaced from the end ofthe discharge conduit 72D and serves to complete the encapsulation ofthe nozzle assembly 71D.

The container 50D further includes a separately formed cap 102D that hasan internal thread 104D threadingly engaged with the closure structurewall second portion 61D. The cap 102D also preferably has a pair of tabs103D (FIG. 10) to aid in turning the cap 102D. Such an arrangement isparticularly useful when the container material is a relatively toughthermoplastic such as polypropylene.

The closure structure wall first portion 59D has, as best illustrated inFIG. 11, an annular shoulder 106D for supporting the cap 102D. To thisend, the cap 102D has a skirt 108D defining a downwardly facing engagingsurface 110D for bearing against the annular shoulder 106D when the cap102D is screwed on the wall second portion 61D toward the wall firstportion 59D.

Preferably, the closure structure wall exterior threads 100D and themating internal threads 104D on the cap 102D are left-hand threads;however, both right-hand threads as well as left-hand threads can beused. When it is desired to gain access to the contents of the container50D, the cap 102D with left-hand threads is simply manipulated to rotatein the conventional "cap opening" direction associated with a right-handthread configuration. Such turning of the cap 102D then causes the cap102D to screw down further onto the container 50D and bear against theannular shoulder 106D. As the cap 102D is thus rotated, part of thethreading torque is transmitted as oppositely directed forces to theannular shoulder 110D on the closure structure wall first portion 59Dand to the closure structure wall second portion 61D. This causes theoppositely directed forces to act across the frangible web 94D and tosever the wall portions from one another along web 94D. Access to thenozzle discharge conduit 72D is thus made possible.

After the upper or wall second portion 61D has been severed from thecontainer and removed therefrom with the cap 102D, the remaining part ofthe now open container 50D appears as illustrated in FIG. 12. The levelof torque required to sever the frangible web 94D depends, of course, onthe size of the cooperating elements, the materials, the specific threadshape and configuration, etc. For a given design, the severance torquecan be established at an approximate level that is great enough toprevent inadvertent severance during normal handling of the container.

When the cap 102D and closure structure second wall portion 61D havebeen removed from the container 50D, the pierceable membrane 72D' in thenozzle assembly 71D may be ruptured or pierced, as with a hypodermicsyringe, cannula, spike, or the like, to permit the container contentsto be withdrawn.

In the novel closure structure 58D described above for the fourthembodiment of the container 50D of the present invention, the insertarticle, such as the nozzle assembly 71D, need not be hermeticallysealed on the top of the container body 52D. That is, there need notnecessarily be a hermetic seal between the container body 52D and theseating shoulder 73D'" of the nozzle assembly base 73D (FIG. 11). It ismerely sufficient that the nozzle assembly 71D be structurally supportedat the opening of the container body 52D.

In the case where there is no hermetic seal between the container body52D and the base 73D of the nozzle assembly 71D, some liquid contentsfrom the container body 52D may find its way upwardly past the base 73D(or may evaporate past the nozzle assembly base 73D) into the annularspace or chamber D between the nozzle assembly base 73D and the wallfirst portion 59D of the closure structure 58D. It is to be realized,however, that a hermetic seal is formed in all instances by the parisonbeing pressed tightly against the peripheral flange 86D of the dischargeconduit 72D below the frangible web 94D. Thus, the contents are alwayshermetically sealed within the container 50D.

In those situations where it is undesirable to permit any temporaryaccumulation of the container contents in the region past the nozzleassembly base 73D, one of two solutions can be provided. First, a truehermetical seal could be established between the parison forming thecontainer body 52D and the base of the nozzle assembly 73D, especiallyat the nozzle assembly seating shoulder 73D'". This can be accomplishedby seating the nozzle assembly 71D with sufficient force and accuracyonto the container body 52D during fabrication.

However, if it is not desired to so critically control the fabricationsteps to ensure a hermetic seal between the nozzle assembly base 73D andthe container body 52D, a second approach to solving the problem may beused as illustrated in FIG. 11. Specifically, the nozzle assembly base73D may be provided with one or more apertures or slots 114D whichcommunicate between the chamber around the first frustoconical wall 73D'and the interior of the container body 52D and provide a drainage means.The aperture or apertures 114D function as very large or gross liquidreturn paths. These apertures 114D are readily observed by one using thecontainer 50D. Thus, it is clear to one using the container 50D that thecontents from the container body 52D may, and are intended to, flow pastthe base 73D of the nozzle assembly 71D and into the annular chamber D.

Further, when the container is positioned in the normal, uprightposition, the contents will readily flow from the chamber D back intothe container body 52D.

In FIG. 11, the tops of the apertures 114D terminate somewhat below thepierceable membrane 72D'. If the apertures 114D are instead fabricatedto extend upwardly, beyond the point illustrated in FIG. 11, all the wayto the pierceable membrane 72D', then when the container 50D isinverted, substantially all of the contents of the container body 52Dwill be able to flow through the nozzle 72D after the membrane 72D' hasbeen ruptured.

METHOD AND APPARATUS FOR MAKING THE FOURTH EMBODIMENT OF THE CONTAINER

The method and apparatus for making the fourth embodiment of thecontainer of the present invention illustrated in FIGS. 10-12 aresimilar to the method and apparatus, respectively, disclosed for makingthe second embodiment of the container 50B discussed above withreference to FIGS. 6 and 7. However, owing to the specific configurationof the nozzle assembly insert article 71D, the method and apparatus canbe somewhat simplified.

Specifically, with reference to FIG. 11, it is seen that the nozzleassembly base 73D has a diameter that is larger than the diameter of theportions of the nozzle assembly above the base wherein the parison ishermetically sealed against the nozzle assembly. The largest diameter ofthe nozzle assembly base 73D occurs at the seating shoulder 73D'". Thus,with such a design, it is relatively easy to place the nozzle assembly71D on the parison forming the opening of the container body 52D and topermit the thusly placed nozzle assembly 71D to then remainself-supporting while subsequent forming and sealing operations areeffected on the parison around the nozzle assembly 71D (such as formingthe frangible web 94D and the overcap structure 92D).

The fabrication method described generally above can be effected withthe following specific steps. First, lower or main sealing mold halvesare provided to operate in substantially the same manner as the mainmold halves 302 and 304 described above with reference to the method forforming the second embodiment of the container 50B (FIG. 7). Similarly,there are provided a pair of holding jaws substantially identical to theholding jaws 312B and 314B described above with reference to the methodof forming the second embodiment of the container 52B (FIG. 7).

Sealing mold halves are provided below the holding jaws and above themain mold halves. Such sealing mold halves are similar to the two setsof mold half pairs 308B, 310B and 340B, 342B described above withreference to the method for forming the second embodiment of thecontainer 50B and illustrated in FIG. 7 except that only one pair ofsealing mold halves is used. Specifically, the two left-hand mold halves308B and 340B are combined into one integral mold half and the tworight-hand mold halves 310B and 342B are combined into one, integralmold half. These combined sealing mold halves are then carried by, butare also movable independently of, the main or lower mold halves thatdefine the cavity for the container body (i.e., identical to main moldhalves 302 and 304 in FIG. 7). Such combined sealing mold halves definea cavity corresponding to the solidified parison forming the closurestructure 58D illustrated in FIG. 11 and are adapted to compressportions of the parison against portions of the insert article or nozzleassembly 71D to form the final closure structure 58D illustrated in FIG.11.

In addition, the sealing mold halves are provided with the necessaryinwardly projecting annular member or forming means for forming thefrangible web 94D. Such forming means are substantially the same asmember 350B described above with reference to fabrication of the secondembodiment of the container 50B illustrated in FIG. 7.

To fabricate the container 50D, the container body portion 52D is formedin the lower or main mold halves by suitable means in the mannerdiscussed above for forming the container bodies 52A, 52B and 52C of thefirst, second and third container embodiments, respectively, asillustrated in FIGS. 1-9. If desired, the container body may then befilled with the desired amount of product in the manner alreadydescribed in detail for the first embodiment of the container 50A withreference to FIGS. 1-5.

Next, a pick up and placement arm, similar to the above-described pickup and placement arm 600A (discussed above with respect to the methodfor forming the first embodiment of the container 50A with reference toFIGS. 1-5), is provided to engage a prefabricated nozzle assembly 71Dand properly position it in the opening of the container body 52D. Thepick up and placement arm is used to position the nozzle assembly 71D inregistration with the container body opening and then lowers the nozzleassembly 71D until the annular seating shoulder 73D'" rests on theparison forming the top 56D of the container body portion 52D asillustrated in FIG. 11. At this point, the main mold halves are stillclosed about the container body 52D. The main mold halves extendupwardly to the horizontal line indicated on the right-hand side of FIG.11, below which horizontal line is shown the designation "MAIN MOLD."

The pick up and placement arm then releases the nozzle assembly 71D ontothe container top 56D at the container body opening and the arm is nextsufficiently retracted to provide the necessary clearance to permit thesealing mold halves to effect the subsequent sealing operation.

At this point, the insert assembly 71D is entirely self-supported on theparison defining the container body top 56D at the opening of thecontainer body 52D. In this respect, the method of positioning theinsert assembly 71D is significantly different from the method used toposition the insert articles for the first embodiment of the containersof the present invention previously described in that the insertassembly does not have to be held in place.

For example, in the first embodiment, the insert articles (such as thefirst embodiment nozzle and cap 75A illustrated in FIG. 4) are retainedby the pick up and placement arm (600A in FIG. 4) while the sealing moldhalves form a frangible web against the insert article per se and effectthe hermetic seal of the parison to the insert article. Only after thefrangible web and hermetic seal have been formed to properly hold theinsert article in place is the pick up and placement arm disengaged fromthe insert article and then retracted.

In contrast, with the method for fabricating the fourth embodiment ofthe container 50D illustrated in FIG. 11, the pick up and placement armreleases the assembly 71D on the top of the container body 52D and isretracted prior to the sealing mold halves being moved inwardly toeffect the formation of the closure structure 58D. During the subsequentstep of placing the nozzle assembly 71D on the top of the container body52D and during the subsequent step of retracting the pick up andplacement arm, the tube of parison extending upwardly beyond the top ofthe main mold halves is, of course, held open by suitable holding jaws(such as holding jaws 312B and 314B illustrated in FIG. 7 forfabricating the above-described second embodiment of the container 50B).

After the nozzle assembly 71D has been properly placed on the top 56D ofthe container body 52D and after the pick up and placement arm has beenretracted from the parison tube extending upwardly from the main moldhalves, the sealing mold halves are extended inwardly above the mainmold halves to form the closure structure 58D around the nozzle assembly71D as illustrated in FIG. 11. During this step, the followingstructural elements are formed substantially simultaneously: (1) thefrangible web 94D, (2) the hermetic seal of portions of the parison tothe nozzle assembly (such as at the wall first portion 59D and theadjacent nozzle flange 86D), (3) the overcap 92, and (4) the externalthreads 100D.

Finally, the lower or main mold halves are returned to the open positionand carry with them the sealing mold halves. The formed container 50D(without the cap 102D) is now clear of the mold assembly and can thus bemoved to suitable apparatus for deflashing. Following deflashing, thecap 102D can be threaded onto the closure structure 58D to form thecompleted container 50D as illustrated in FIGS. 10 and 11.

THE CONTAINER: FIFTH EMBODIMENT

A fifth embodiment of the container, designated generally by referencenumeral 50E, is illustrated in FIGS. 13 and 14. Elements of the fifthembodiment of the container 50E that are functionally analogous toelements of the fourth embodiment of the container 50D are designated byidentical reference numerals with the exception that the referencenumerals for the fifth embodiment are followed with the capital letterE, whereas the reference numerals for the fourth embodiment are followedby the capital letter D.

The container 50E has a body 52E generally similar to the body 52D ofthe fourth embodiment of the container 50D described above withreference to FIGS. 10-12. A composite insert article comprising adischarge conduit 71E at the opening of the container body portion 52Eis provided. The discharge conduit 71E includes a lower or first,hollow, cylindrical portion 73E and a reduced diameter, hollow,cylindrical portion 72E above the lower portion 73E. The lower portion73E has a seating shoulder 73E'" for engaging a first annular shoulder57E on the top portion 56E of the container body 52E. The lower portion73E also has an annular rib 86E to ensure proper sealing and gripping ofthe conduit 71E by the parison.

The top portion 72E of the discharge conduit 71E has exterior threads130E. An inner or first cap 120E is secured to the portion 72E of thedischarge conduit 71E. To this end, the cap 120E includes internalthreads 132E for engaging the exterior threads 130E on the dischargeconduit 71E.

The interior diameters of the lower portion 73E and of the upper portion72E of the discharge conduit 71E are relatively large and provide across-sectional flow passage area that is a substantial percentage ofthe area of the opening of the container body 52E.

The container 50E is provided with a closure structure 58E that isfunctionally analogous to the closure structure 58D described above withreference to the fourth embodiment of the container 50D illustrated inFIGS. 10 and 11. Specifically, the closure structure 58E of the fifthembodiment of the container 50E illustrated in FIGS. 13 and 14 comprisessolidified parison that has been molded in the particular illustratedconfiguration with portions of the parison formed to engage the side ofthe discharge conduit 71E. The top of the closure structure 58E iscompletely sealed over the discharge conduit 71E with an integral coveror overcap structure 92E that is spaced from the first cap 120E. Thus,the closure structure 58E has to be broken to permit access to thedischarge conduit 71E and cap 120E.

To this end, the overcap structure 92E is joined to the lower portion ofthe closure structure 58E by means of a frangible web or reducedthickness portion 94E of the molded thermoplastic material. The web 94Ejoins a wall lower or first portion 59E to a wall upper or secondportion 61E and the exterior surface of the frangible web 94E is seen todefine an annular notch.

An exterior thread 100E is defined in the wall upper or second portion61E of the closure structure 58E. A second cap 102E is provided with adownwardly depending skirt 108E. An internal thread 104E for engagingthe exterior thread 100E on the closure structure 58E is defined by theskirt 108E.

In addition, the bottom edge of the second cap 102E defines an annular,downwardly facing, engaging surface 110E. The top 56E of the containerbody 52E is provided with an upwardly facing second annular shoulder106E for engagement by the engaging surface 110E of the cap 102E. Thecap 102E is also preferably provided with tabs 103E (FIG. 13) to aid inturning the cap.

Preferably, the thread on the cap 102E and the thread on the closurestructure 58E are left-hand threads so that screwing the cap 102E in theconventional right-hand "unscrewing" direction will cause the cap toscrew further downwardly onto the closure structure 58E. This willrupture the frangible web 94E of the closure structure 58E in a manneranalogous to that described above for the fourth embodiment of thecontainer 50D with reference to FIGS. 10-12.

When the frangible web 94E has been ruptured to sever the wall upper orsecond portion 61E from the wall lower or first portion 59E, the severedwall second portion 61E and the engaged second cap 102E are removed toprovide access to the first cap 120E on the discharge conduit 71E.

The thread 130E on the discharge conduit 71E and the thread 132E on thefirst cap 120E are preferably right-hand threads to permit the cap 120Eto be removed from the discharge conduit 71E with the conventionalunscrewing rotation to provide access to the container contents.

METHOD AND APPARATUS FOR MAKING THE FIFTH EMBODIMENT OF THE CONTAINER

The method and apparatus for making the fifth embodiment of thecontainer 50E are substantially the same as the method and apparatus,respectively, for making the fourth embodiment of the container 50Ddescribed above with reference to FIGS. 10-12. In FIG. 14, on the righthand side of the figure, there is illustrated a horizontal line belowwhich is the designation "MAIN MOLD" indicating that the tops of themain mold halves lie at that horizontal line and that the main moldhalves extend downwardly from that line to define the cavity for formingthe container body 52E. The upper sealing mold halves extend upwardlyfrom the horizontal line.

To fabricate the container 50E, the container body 52E is fabricated ina manner analogous to that for fabricating the container body 52D of thefourth embodiment of the container 50D as described above with referenceto FIGS. 10 and 11. The body 52D may be filled if desired.

After the container body 52E is formed, a closure assembly, constitutedby discharge conduit 71E threadingly engaged with the first cap 120E, isplaced by a suitable pick up and placement arm on the container body topportion 56E so that the discharge conduit 71E is self-supporting on itsseating shoulder 3E'". The pick up and placement arm is then retractedto provide clearance for the inward closure of the upper sealing moldhalves to form the closure structure 58E in the shape illustrated inFIG. 14. The upper sealing mold halves form (1) the frangible web 94E,(2) the hermetic seal regions of the closure structure wall firstportion 59E to the discharge conduit 71E, (3) the exterior threads inthe closure structure wall second portion 61E, and (4) the integralovercap cover structure 92E.

Next, the sealing mold halves and the main mold halves are retracted torelease the container 50E for deflashing and to permit the second cap102E to be threaded onto the container 50E.

FURTHER MODIFICATIONS TO THE CONTAINER EMBODIMENTS

Each of the five embodiments of the container of the present inventiondescribed above has been illustrated as having a container body with oneopening. It is to be realized that the container of the presentinvention may include more than one such opening or aperture, and thateach of a plurality of such openings or apertures may be provided withan insert article and with partially or fully encapsulating closurestructures of the types disclosed herein.

The embodiments of the novel container of the present invention, themethods for making the containers, and the apparatus for making thecontainers have been described above with reference to particularmulti-piece insert articles which are retained by or within the closurestructure at the top of the container body. Such insert articles neednot necessarily be multi-piece assemblies, however. Rather, a single,unitary piece may be provided for retention within the closurestructure. Such a unitary piece may or may not have a dispensingaperture therethrough, as desired.

If desired, such a single piece retained within the closure structuremay be an impervious stopper plug insert or other such article. Aftersevering the closure structure at the frangible web, the stopper or pluginsert could be removed to permit access to the container contents perse. Alternatively, the stopper or plug insert could remain in the top ofthe container and a hypodermic syringe, cannula, spike or the like couldbe inserted through the stopper to effect extraction of the contentsfrom the container.

Each novel closure structure of the containers of the present inventionis provided with a frangible web formed against a portion of the insertarticle. Further, as with the first embodiment of the container, it isnot required that the thermoplastic material forming the closurestructure extend above the top of the insert article. Such an embodimentthus differs from containers fabricated by other methods wherein afrangible web is formed against the pick up arm above the insertarticle. Thus, such a container of the present invention can befabricated with less material.

Further, when a portion of the insert article extends upwardly beyondthe frangible web and beyond the top of the upper end of the closurestructure (as with the first embodiment of the container illustrated inFIGS. 1 and 2), the exposed, projecting portion of the insert articlecan be easily grasped and manipulated to open the container by breakingthe frangible web.

From the foregoing, it will be observed that numerous variations andmodifications may be effected without departing from the true spirit andscope of the novel concept of the invention. It is to be understood thatno limitation with respect to the specific articles, apparatus, andmethods illustrated herein is intended or should be inferred. It is, ofcourse, intended to cover by the appended claims all such modificationsas fall within the scope of the claims.

What is claimed is:
 1. In a method for forming a container from anextruded length of parison in the form of a vertically oriented,elongated, hollow tube positioned in a closed main mold whilemaintaining an opening at the top of a remaining length of parison abovethe closed main mold for accommodating an inserted blowing assembly bywhich the container body is blow molded, for thereafter removing saidblowing assembly from said parison top opening, and for then sealing thetop of the molded container;the improvement in the method characterizedin that, after said blowing assembly is removed from said parison topopening, the method further includes the following steps: (a)temporarily maintaining said top opening in said parison; (b)positioning an insert article within said hollow tube of parison at thetop of said molded container body; and (c) engaging at least some ofsaid remaining length of parison around the periphery of the top of themolded container body and compressing the engaged parison against theperiphery of at least a portion of said insert article to hermeticallyseal the container to the insert article which remains in sealedengagement at the completion of the container formation while permittingsubsequent removal of at least a portion of said insert article, saidcompressing step also including compressing said parison against theperiphery of said insert article below the top of said insert article toform a reduced thickness region defining a peripheral frangible webspaced below the top of the insert article.
 2. In a method for forming acontainer from an extruded length of parison in the form of a verticallyoriented, elongated, hollow tube positioned in a closed main mold whilemaintaining an opening at the top of a remaining length of parison abovethe closed main mold as the container body is formed form the parison inthe main mold and for thereafter sealing the top of the moldedcontainer;the improvement in the method characterized in that, aftersaid container body is formed, said step of sealing said containerincludes the following steps: (a) temporarily maintaining said topopening in said parison; (b) positioning an insert article within saidhollow tube of parison at the top of said molded container body; and (c)engaging at least some of said remaining length of parison around theperiphery of the top of the molded container body and compressing theengaged parison against the periphery of at least a portion of saidinsert article to form a peripheral wall member and seal the containerto the insert article which remains in sealed engagement at thecompletion of the container formation while permitting subsequentremoval of at least a portion of said insert article, said compressingstep also including compressing a portion of said parison against theperiphery of said insert article below the top of said insert article toform a reduced thickness region defining a peripheral frangible webjoining first and second portions of the formed wall member spaced belowthe top of the insert article whereby force may be applied to said firstand second portions to sever the frangible web and break at least aportion of said seal at said insert article.
 3. The method in accordancewith claim 2 in which step (c) includes encapsulating only a part ofsaid insert article whreby force may be applied directly to theunencapsulated part of said insert article for transmitting a force toone of said first and second portions of the formed wall member forsevering said frangible web.
 4. The method in accordance with claim 2,in which step (c) includes completely encapsulating said insert articlewith said parison whereby one of said first and second portions of theformed wall member can be grasped while applying force to sever thefrangible web.
 5. The method in accordance with claim 2in which step (b)includes (1) first providing an insert article comprising a dispensingnozzle having a base and having a discharge conduit projecting abovesaid base and (2) subsequently positioning said nozzle to seat saidnozzle base on the top of said container body; in which step (c)includes (1) completely encapsulating said nozzle discharge conduit withsaid parison, (2) molding an external thread in said wall member secondportion, and (3) molding an annular shoulder in said wall member firstportion; and in which said method includes the further steps, after step(c), of (d) providing a cap having a skirt defining (1) an engagingsurface for bearing against said annular shoulder of said wall memberfirst portion and (2) an internal thread for threadingly engaging saidexternal thread on said wall member second portion; and (e) screwingsaid cap onto said wall member second portion.
 6. The method inaccordance with claim 2 in which the container is formed by blowmolding.
 7. The method in accordance with claim 2in which the top ofsaid container body is formed with an upwardly facing first annularshoulder and with an upwardly facing second annular shoulder; in whichstep (b) includes (1) first providing an insert article comprising adischarge conduit with an exterior thread and a threadingly engagedfirst cap and (2) subsequently positioning said conduit to seat saidconduit on said container body first annular shoulder; in which step (c)includes (1) completely encapsulating said discharge conduit and firstcap with said parison, and (2) molding an external thread in said wallmember second portion; and in which said method includes, after step(c), the following further steps: (d) providing a second cap having askirt defining (1) an engaging surface for bearing against said secondannular shoulder of said container body and (2) an internal thread forthreadingly engaging said external thread on said wall member secondportion; and (e) screwing said second cap onto said wall member secondportion.
 8. A method for forming an upright and sealed but emptycontainer having a top insert article molded therein, said methodcomprising the steps of (a) providing an extruded length of parison inthe form of a vertically oriented, elongated, hollow tube; (b) providingand closing a main mold assembly around a portion of said length ofparison while gripping a portion of said parison extending upwardlyabove the closed main mold assembly to maintain an opening at the top ofthe length of parison; (c) providing and extending a blowing assemblypartially into said length of parison through said parison top openingwhile sealingly engaging the inner surface of said parison with saidblowing assembly; (d) discharging pressurized gas into said parison fromsaid blowing assembly to mold the container body in the closed main moldassembly; (e) retracting said blowing assembly from said parison topopening; (f) providing and positioning said insert article within saidhollow tube of parison at the top of the molded container body; (g)compressing a peripheral portion of the parison around at least aportion of said insert article to hermetically seal the container bodyto the insert article; and (h) compressing part of said peripheralportion of said parison further against said insert article to form areduced thickness region defining a peripheral frangible web wherebyforce may be applied to the subsequently solidified parison to seversaid frangible web and thereby facilitate destruction of at least aportion of said hermetic seal at said insert article.
 9. The method inaccordance with claim 8 in which steps (g) and (h) are performedsubstantially simultaneously.
 10. The method in accordance with claim 8in which step (f) includes providing said insert article in the form ofa nozzle assembly comprising (1) a nozzle and a connected base and (2) acap mounted on said nozzle above said base; in which step (g) includescompressing said peripheral portion of parison against a portion of saidnozzle base and also against a portion of said cap; and in which step(h) includes compressing said part of said peripheral portion of saidparison further against said cap to form said frangible web.